Tape measure with reinforced tape blade

ABSTRACT

A tape measure including a reinforced or coated tape measure blade is provided. The reinforcement layer is thicker than the metal inner layer of the tape blade. The reinforcement layer provides a reinforced tape blade such that the elongate tape blade may have a pinch load threshold of greater than 30 lbs. and/or a pinch height at break of less than 1.5 mm.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

The present application is a continuation of U.S. application Ser. No.16/360,894, filed Mar. 21, 2019, which is a continuation ofInternational Application No. PCT/US2019/021012, filed on Mar. 6, 2019,which claims the benefit of and priority to 62/639,743, filed on Mar. 7,2018, which are incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of tools. Thepresent invention relates specifically to a tape measure, measuringtape, retractable rule, etc., that includes a tape measure blade with areinforcing layer on the tape blade.

Tape measures are measurement tools used for a variety of measurementapplications, including in the building and construction trades. Sometape measures include a graduated, marked blade wound on a reel and alsoinclude a retraction system for automatically retracting the blade ontothe reel. In some such tape measure designs, the retraction system isdriven by a coil or spiral spring that is tensioned, storing energy asthe tape is extended, and that releases energy to spin the reel, windingthe blade back onto the reel such that automatic or non-manual taperetraction is provided. In some other tape measure designs, retractionof the tape is controlled via a manual crank, and such tape measureblades tend to have a long length.

SUMMARY OF THE INVENTION

This application relates to various tape measure embodiments discussedherein.

In one embodiment, a tape measure is provided. The tape measure includesa housing, a reel rotatably mounted within the housing and an elongateblade wound around the reel. The elongate blade includes an elongatemetal core having an upper surface, a lower surface and a firstthickness, T1, measured between the upper surface and the lower surface,and the upper surface includes a concave curved section and the lowersurface includes a convex curved section. The elongate blade includes anupper reinforcement layer coupled to and covering at least a portion ofthe upper surface of the elongate metal core, and the upperreinforcement layer includes a second thickness, T2, and an uppersurface defining the uppermost surface of the elongate blade. Theelongate blade includes a lower reinforcement layer coupled to andcovering at least a portion of the lower surface of the elongate metalcore, and the lower reinforcement layer has a third thickness, T3, and alower surface defining the lowermost surface of the elongate blade. Theelongate blade includes an ink layer located between the upper surfaceof the elongate metal core and the upper reinforcement layer forming aseries of measurement markings. The thicknesses are such that T2+T3≥T1,and the elongate blade has a pinch load threshold of greater than 30lbs. The tape measure includes a retraction mechanism coupled to thereel and configured to driving rewinding of the elongate blade on to thereel. The tape measure includes a hook assembly coupled to an outer endof the elongate blade.

In another embodiment, a tape measure is provided. A tape measureincluding a housing, a reel rotatably mounted within the housing and anelongate blade wound around the reel. The elongate blade includes anelongate metal core having an upper surface, a lower surface and a metalthickness measured between the upper surface and the lower surface. Theelongate blade includes polymer reinforcement layer coupled to a surfaceof the elongate metal and extending contiguously lengthwise for at least6 ft. along a length of the elongate metal core, and the polymerreinforcement layer has a polymer reinforcement layer thickness. Theelongate blade includes an ink layer located between the elongate metalcore and the polymer reinforcement layer, and the ink layer forms aseries of measurement markings. The elongate blade has a pinch loadthreshold of greater than 30 lbs. The tape measure includes a retractionmechanism coupled to the reel and configured to driving rewinding of theelongate blade on to the reel, and a hook assembly coupled to an outerend of the elongate blade.

In another embodiment, a tape measure is provided. The tape measureincludes a housing, a reel rotatably mounted within the housing and anelongate blade wound around the reel. The elongate blade includes anelongate metal core having an upper surface, a lower surface and a metalthickness measured between the upper surface and the lower surface. Theelongate blade includes a polymer reinforcement layer at least partiallysurrounding the elongate metal core when viewed in cross-section andextending contiguously lengthwise for at least 6 ft. along a length ofthe elongate metal core, and the polymer reinforcement layer has apolymer reinforcement layer thickness. The elongate blade includes anink layer located between the elongate metal core and the polymerreinforcement layer, and the ink layer forms a series of measurementmarkings. The polymer reinforcement layer thickness is greater than themetal thickness. The tape measure including a retraction mechanismcoupled to the reel and configured to driving rewinding of the elongateblade on to the reel and a hook assembly coupled to an outer end of theelongate blade.

Additional features and advantages will be set forth in the detaileddescription which follows, and, in part, will be readily apparent tothose skilled in the art from the description or recognized bypracticing the embodiments as described in the written description andclaims hereof, as well as the appended drawings. It is to be understoodthat both the foregoing general description and the following detaileddescription are exemplary.

The accompanying drawings are included to provide further understandingand are incorporated in and constitute a part of this specification. Thedrawings illustrate one or more embodiments and, together with thedescription, serve to explain principles and operation of the variousembodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a left side perspective view of a tape measure, according toan exemplary embodiment.

FIG. 2 is a left side perspective view of the tape measure of FIG. 1with a portion of the tape measure housing removed, according to anexemplary embodiment.

FIG. 3 is a cross-sectional view of a reinforced tape blade of the tapemeasure of FIG. 1 , according to an exemplary embodiment.

FIG. 4 is a photograph showing the set up for the tape blade pinch test,as discussed below.

FIG. 5 is a photograph showing engagement between a mandrel and a tapeblade during a pinch test, as discussed below.

FIGS. 6-9 show various graphs of the data from Table 1 below.

DETAILED DESCRIPTION

Referring generally to FIGS. 1-3 , various embodiments of a tape measureare shown and described. Various embodiments of the tape measurediscussed herein include an innovative coated or laminated metal bladefor a tape measure. Specifically, the tape measure blade discussedherein includes a relatively thick layer of material (e.g., a polymermaterial) coupled to upper and/or lower surfaces of an inner metal layerof the tape blade. The thickness, hardness, elasticity, and/or materialtype, etc. of the polymer reinforcement layer is selected to provide atape measure blade having improved crack or break resistance as comparedto tape measure blades having other layer thicknesses or otherreinforcement materials.

In particular, Applicant has found that by forming a tape blade wherethe total thickness of the polymer reinforcement layer material (e.g.,the combined thickness of both the upper and lower layers of polymerreinforcement layer material) is greater than the thickness of the innermetal layer provides a tape blade particularly resistant to breakage(e.g., as tested utilizing a pinch test described below). Without beingbound by a particular theory, in at least some embodiments, Applicanthypothesizes that the thick reinforcement layer discussed herein limitsthe radius of curvature that the metal material of the tape blade isexposed to when crimped/bent and thereby reduces the risk that metalmaterial will crack. In this state, Applicant's theorize that the pinchforce required to crack the tape is the force required to compress thepolymer reinforcement layer such that the bend radius of the steel innerlayer decreases to the point at which cracks develop. Further, in atleast some embodiments, Applicant hypothesizes that the thickreinforcement layer discussed herein acts to hold the metal materialtogether in the event of small crack formation, which limits crackpropagation and tape blade breakage.

In general, Applicant understands that the art has typically viewedincreasing the size of the tape measure housing as undesirable due tothe difficulty gripping, holding, transporting, etc., a large sized tapemeasure. For at least this reason, Applicant understands that the arthas typically not seen increasing tape blade reinforcement layerthickness as a viable means for strengthening the tape blade due to theincreased size of such blades when wound onto a reel within a tapemeasure housing. Accordingly, at least in some embodiments, thereinforced tape blade discussed herein is used in conjunction with oneor more other components designed to reduce the size of other internalcomponents located within the tape measure housing, which in turn allowsmore of the space within the tape measure housing to be occupied by thethickly coated, reinforced tape measure blade for a given outer housingsize dimension.

In specific embodiments, the tape measure may include two or more smalldiameter coil springs (e.g., power springs) as part of the tape bladeretraction system, which in turn allows the size of the outer diameterof the housing to be reduced, as compared to a similar tape measureusing one large coil spring for retraction. Similarly, in specificembodiments, the tape measure may include a reduction gear train thatallows for a smaller diameter, more energy dense spring as compared to asimilar tape measure using a coil spring with no gear train forretraction.

In further specific embodiments, the tape blade has a length suitablefor retraction via a spring based retraction system. In specificembodiments, the length of the tape blade is less than 50 feet or more,specifically less than 40 feet. In specific embodiments, the length ofthe tape blade is 35 ft., 30 ft., 25 ft., or 16 ft. In further specificembodiments, the tape blade has a curved cross-sectional shape. In suchembodiments, the tape blade that has a shape in which the upper surfaceis a concave curved surface and the lower surface of the blade is aconvex curved surface. In further specific embodiments, the tape bladeis structured to have a relatively significant stand-out length (i.e.,the length of tape blade that can extend from the housing whilesupporting itself without buckling), and in some such embodiments, thetape stand out is at least 1 foot, at least 3 feet, at least 6 feet,less than 10 feet, etc. Applicant believes these structuresdifferentiate the tape measure of the present disclosure from very long(e.g., 100 ft. or more) crank-retracted tape measures.

Referring to FIG. 1 and FIG. 2 , a length measurement device, such astape measure 10, is shown according to an exemplary embodiment. Tapemeasure 10 includes an elongated tape blade, shown as coilable tapeblade 14, and a housing 18. In general, tape blade 14 is an elongatestrip of material including a plurality of graduated measurementmarkings (see e.g., FIG. 4 ), and in specific embodiments, tape blade 14is an elongate strip of metal material (e.g., steel material) thatincludes an outer most end coupled to a hook assembly, shown as hookassembly 26. As discussed in more detail below, tape blade 14 mayinclude various polymer layers or reinforcing layers (e.g., polymercoating layers, laminated polymer layers, adhesive applied films, etc.)to help protect tape blade 14 from cracking during whip or pinch.Further, tape blade 14 may include any combination of tape bladefeatures of the various embodiments discussed herein.

As shown in FIG. 1 , a variable-length extended segment 22 of the tapeblade 14 is retractable and extendable from the housing 18. A hookassembly 26 is fixedly coupled to an outer end portion 30 of tape blade14.

As shown in FIG. 2 , the non-extended portion of tape blade 14 is woundonto a reel 34, which is surrounded by housing 18. Reel 34 is rotatablydisposed about an axis 38 of tape measure 10, and a retraction mechanism42 is coupled to reel 34 and configured to drive reel 34 about rotationaxis 38 which in turn provides powered retraction of tape blade 14.Retraction mechanism 42 may include one or more elongated spiral springsthat provide the retraction energy to retraction mechanism 42. Inanother embodiment, retraction mechanism 42 includes an electric motorin place of or in combination with a spring. A tape lock 46 is providedto selectively engage tape blade 14, which acts to restrain retractionmechanism 42 such that extended segment 22 of tape blade 14 remains at adesired length.

In specific embodiments, retraction mechanism 42 is configured toprovide for a relatively small housing size, despite the increased bladethickness. In one embodiment, retraction mechanism 42 includes two ormore spiral springs (e.g., power springs) which will deliver a desiredlevel of torque while decreasing the outer diameter of the spaceoccupied by the springs (at least as compared to the outer diameter of asingle spiral spring that delivers the same level of torque). In otherembodiments, retraction mechanism 42 includes a reduction gear trainlocated between the tape reel and spring such that each rotation of thetape reel results in less than one rotation of the spring. Thisarrangement allows for a smaller diameter, more energy dense spring ascompared to a similar tape measure using a coil spring with no geartrain for retraction.

By utilizing one or more size reduction mechanisms, e.g., gearing,multiple springs, etc., a thicker tape blade may be used without thesize of the housing growing for the same length of tape. In someembodiments, a coil spring having a width wider than the width of tapeblade 14 may be used, which allows for a lower diameter/height spring tobe used. In some such embodiments, the coil spring has a width between110% and 150% of the width tape blade 14, specifically, the coil springhas a width between 120% and 135% of the width tape blade 14, and morespecifically, the coil spring has a width of approximately 130% of thewidth tape blade 14. In this way, the spring may be of a smaller height,allowing reduction of the height of the housing relative tosmaller-width, but larger diameter spring, which may allow for a smallerheight housing with a thicker tape.

Referring to FIG. 1 , housing 18 includes a first side wall 50, a secondside wall 54, and a peripheral wall 58 connecting first side wall 50 andsecond side wall 54. First side wall 50, second side wall 54, andperipheral wall 58 define an internal cavity 62, shown in FIG. 2 , inwhich reel 34 and retraction mechanism 42 are housed. Referring to FIG.1 , first side wall 50 and second side wall 54 have a substantiallycircular profile 66. In other embodiments, the side walls may berectangular, polygonal, or any other desired shape. Portions of thehousing 18 may be co-molded or separately formed of a resilientmaterial, such as a natural or synthetic rubber. In the illustratedconstruction, housing 18 is formed with housing bumpers 70 and a supportleg 74 which extend from a lower portion 78 of the peripheral wall 58.

A slot 82 is defined along a forward portion 86 of peripheral wall 58.Slot 82 provides an opening in the tape measure housing which allowstape lock 46 to extend into housing 18. In addition, slot 82 provides alength sufficient to allow tape lock 46 to be moved relative to housing18 between locked and unlocked positions.

Below the slot 82, a tape port 90 is provided in peripheral wall 58.Tape port 90 has an arcuate shape 94, corresponding to an arcuatecross-sectional profile of tape blade 14. The tape port 90 allows forthe retraction and extension of tape blade 14 to and from the internalcavity 62 defined within housing 18.

As shown in FIGS. 1 and 2 , tape measure 10 includes a finger guardassembly 98. Finger guard assembly 98 includes a guard 102 and a guardsupport member 106. As shown in FIG. 1 , the portions of guard 102external to housing 18 are substantially U-shaped and extend downwardfrom housing 18. As shown in FIG. 2 , when tape 14 is in the retractedposition, a rear surface of hook assembly 26 abuts guard 102.

Referring to FIG. 3 , a cross-sectional view of tape blade 14 is shown.Tape blade 14 includes a core or inner layer 110 formed from a thin,elongate strip of metal material. In a specific embodiment, inner layer110 is formed from a strip of steel material. In a specific embodiment,inner layer 110 has a thickness, T1, between 0.09 mm and 0.2 mm,specifically, between 0.1 mm and 0.18 mm (with up to a 25% thicknessvariation), and more specifically of 0.1 mm to 0.13 mm. Ina specificembodiment, T1 is between 0.105 and 0.115 mm. In another specificembodiment, T1 is between 0.120 mm and 0.130 mm, and in another specificembodiment, T1 is between 0.10 mm and 0.11 mm. Inner layer 110 may beformed in a concavo-convex configuration (as shown in FIG. 3 ), whichmay provide for improved tape standout. Inner layer 110 may be analloyed spring steel, alloyed high strength steel, etc. In oneembodiment, the steel is of a hardness between 50-54 RHC (Rockwellhardness C). In another embodiment, the steel is of a hardness between45-60 RHC.

In various embodiments, tape blade 14 includes at least one reinforcinglayer coupled to at least one of the upper surface and/or lower surfaceof inner metal layer 110. In the specific embodiment shown in FIG. 3 ,tape blade 14 includes an upper reinforcing layer, shown as upper layer112, coupled (e.g., attached, bonded, glued, etc.) onto the concaveupper surface of inner metal layer 110 and a lower reinforcing layer,shown as lower layer 114, coupled (e.g., attached, bonded, glued, etc.)onto the convex lower surface of inner metal layer 110. In variousembodiments, layers 112 and 114 are formed from a polymer material, andin a specific embodiment, are formed from a nylon material.

As shown, layer 112 has an upper surface 116 that defines the uppermostsurface of tape blade 14, and layer 114 has a lower surface 118 thatdefines the lowermost surface of tape blade 14. Ink layers 119 may belocated between layers 112 and/or 114 forming measurement markings orindicia (see FIG. 4 ). In specific embodiments, layers 112 and 114 areformed from a material that has a modulus of elasticity less than themodulus of elasticity of the metal material of inner layer 110. Inspecific embodiments, layers 112 and 114 are formed from a material thathas a hardness less than the hardness of the metal material of innerlayer 110. In specific embodiments, the coating layers discussed hereinare formed from a nylon 12 material and/or a nylon 6/6 material.

In various embodiments, layers 112 and/or 114 are formed from anextruded polymer material and specifically an extruded nylon material.In such embodiments, the polymer for layers 112 and/or 114 are extrudedin liquid form onto inner metal core 110, and cured or otherwisesolidified to form layers 112 and/or 114.

In other embodiments, layers 112 and/or 114 are formed from a sheet offilm material adhered to inner metal core 110. In various embodiments,layers 112 and/or 114 are formed from a sheet of polymer material thatis bonded to the surfaces of inner metal core 110 using an adhesivematerial. In various embodiments, the sheet of polymer material isformed from a thermoplastic material, such as PET, and the adhesive maybe an acrylic adhesive or a polyester thermoset adhesive.

In specific embodiments, layers 112 and/or 114 are formed from sheet ofMylar A material from DuPont and the adhesive is a polyester thermosetavailable from Bostik, Inc., and prototypes 4 and 5 shown in Table 1(below) utilize such materials for layers 112 and/or 114. In addition tothe pinch testing, Applicant has found that these materials result inlayers 112 and 114 with high bonding such that these layers tear beforedelaminating.

In other specific embodiments, layers 112 and/or 114 are formed from8412 Tape, which is a PET film with acrylic adhesive, available from The3M Company, and prototypes 6 and 7 shown in Table 1 utilize thesematerials for layers 112 and/or 114. It should be understood that whileFIG. 3 shows a tape blade with reinforcement layers on both the upperand lower surfaces of inner metal core 110, the various reinforcementlayer designs, thicknesses, pinch test performances, etc. may beaccomplished via a reinforcement layer meeting one or more of the designparameters discussed herein located on only one side of inner metal core110.

As shown in FIG. 3 , in specific embodiments, layers 112 and/or 114 donot wrap around the side edges of inner metal core 110. In fact, intesting versions of layers 112 and/or 114 that utilize adhesive-bondedfilm material, Applicant has found that edge wrapping increases thechance of delamination of layers 112 and/or 114 during pinch testing,but that delamination does not occur without edge wrapping. In somedesigns coverage of the edges of inner metal core 110 may be desirable.In such embodiments, an extruded polymer that forms layers 112 and/or114 also covers the edge surfaces. In some embodiments utilizinglaminated film for layers 112 and/or 114, a separate, narrow sheet offilm material may be applied to cover each of the edge surfaces of innermetal core 110.

As shown in FIG. 3 , layer 112 has a thickness, T2, and layer 114 has athickness, T3. In specific embodiments, the total thickness of the tapeblade reinforcement layer(s) (i.e., the combined thickness of layers 112and 114, T2+T3) is greater than T1. In specific embodiments, T2+T3 isgreater than 1.5T1. In specific embodiments, T2+T3 is between 1.5T1 and3.5T1, and in even more specific embodiments, T2+T3 is between 1.5T1 and2.5T1. Applicant has found that the substantial thickness of layers 112and 114 relative to the thickness of core layer 110 limits the radius ofcurvature experienced by layer 110 during pinch tests (see Pinch Testdescription below), which in turn limits the likelihood that layer 110will crack when pinched or crimped.

In specific embodiments, T2+T3 is between 0.2 mm and 0.4 mm. In aspecific embodiment, T2+T3 is between 0.2 mm and 0.25 mm, and morespecifically is between 0.21 mm and 0.23 mm. In one embodiment, T2 issubstantially equal to T3 (e.g., is within 5% of T3). In anotherembodiment, T2 is greater than T3 (e.g., is more than 5% greater thanT3). In another embodiment, T3 is greater than T2 (e.g., is more than 5%greater than T2).

In other embodiments, the reinforcement layer thickness can be expressedas the ratio of total tape blade thickness (T1+T2+T3) to the thicknessof inner metal core 110 (T1). In various embodiments. (T1+T2+T3)/T1 isgreater than or equal to 2, and specifically greater than or equal to2.5. In more specific embodiments, (T1+T2+T3)/T1 is between 2.5 and 4,and more specifically between 2.5 and 3.5.

In one embodiment, the total tape blade thickness (inclusive of all ofthe reinforcement layers and the core layer, i.e., T1+T2+T3) is between0.3 mm and 0.5 mm. In a specific embodiment, T1+T2+T3 is between 0.3 mmand 0.35 mm, and specifically is 0.33 mm (e.g., 0.33 mm plus or minus5%). As shown in Table 1 below, prototype 1 has a total thickness of0.33 mm and a pinch load threshold of greater than 30 lbs. In particularembodiments, Applicant believes that this design represents aparticularly advantageous balance between strength enhancing tape bladethickness without unduly increasing tape housing size or manufacturingcosts.

In one embodiment, one or more reinforcing layers, such as layers 112and 114, are applied over the entire length of inner layer 110.

In one embodiment, one or more reinforcing layers, such as layers 112and 114, are applied over at least 6 feet of the length of inner layer110, specifically over at least 8 feet of the length of inner layer 110,and more specifically over at least 10 feet of the length of inner layer110. In specific embodiments, these lengths are contiguous lengths ofthe material forming layers 112 and 114. Such designs may provideincreased tear resistance in areas of the tape blade 14 prone toincreased wear, while maintaining compactness of the tape relative to atape blade that has the coating over the entire length. In oneembodiment, layers 112 and 114 begin at the end of the tape blade 14proximate the hook. In another embodiment, the reinforcement layerstarts at a location of the blade spaced apart from the end proximatehook assembly 26.

In some embodiments, layers 112 and/or 114 do not have uniformthicknesses along the width and/or length of tape blade 14. In some suchembodiments, layers 112 and/or 114 may be applied in a pattern (e.g., ahoneycomb pattern, a checkered pattern, etc.) where there are portionsof thicker and thinner coating distribution across both the length andwidth of the tape blade 14. In such embodiments, T2 and T3 shown in FIG.3 represent the thickness measured through the thickest portion of thecoating pattern. In some such embodiments, the ranges of T2 and T3discussed herein represent the maximum thickness of layers 112 and 114at any portion along the length of tape blade 14. For example, in somesuch embodiments, the combined maximum coating and blade thickness maybe 0.33 mm, but in other areas along the length and width of the tapeblade, the coating and blade thickness will be less (e.g., as measuredat the thinner coating portions of the coating pattern). In otherembodiments, the ranges of T2 and T3 discussed herein represent theaverage thickness of layers 112 and 114 measured at all of the thickestportions of the coating pattern along the length and width of tape blade14.

One or more reinforcing layers, such as layers 112 and 114, may beapplied as a laminate, nylon extrusion, film attached with adhesive,power/spray on coating. In one embodiment, the reinforcement layer(s)are configured such that even if the steel core were to fracture, thereinforcement layer is configured to contain the steel core and tomaintain the integrity of the blade (e.g., the reinforcement layer willtend not to tear).

As will be discussed in more detail below, layers 112 and 114 aredesigned to provide high levels of pinch test performance, representedby a pinch load threshold (which is the pinch test force required tobreak a given tape blade) and a pinch height at break. In variousembodiments, tape blade 14 has a pinch load threshold greater than orequal to 30 lbs., and specifically a pinch load threshold greater than30 lbs. and less than 50 lbs. In a specific embodiment, the pinch loadthreshold is greater than 30 lbs. and less than 35 lbs. In variousembodiments, tape blade 14 has a pinch height at break of less than 1.5mm.

Pinch Test and Examples

Testing data for a number of tape measure blades designs havingdifferent total thicknesses, reinforcement layer thicknesses andreinforcement layer types are shown in Table 1, below. As shown in Table1, the prototype designs are specific exemplary embodiments ofinnovative tape blades with reinforcing layers designed as discussedherein. The other data sets show testing of current commerciallyavailable tape measures. As can be seen, the various prototype designsperform significantly better during pinch test than the prior artdesigns, while having higher overall tape thickness (resulting fromthicker reinforcing layers) but lower steel thicknesses. From thistesting Applicant has concluded that significantly better pinch testperformance can be achieved via increases in reinforcing layer thicknesswhile decreasing steel thickness. In addition, Applicant has determinedthat designing a tape blade in which the pinch load threshold is greaterthan 30 lbs., and specifically between 30 lbs. and 50 lbs. provides adesirable balance between high enough pinch test performance whilemaintaining a satisfactorily low overall tape blade thickness.

TABLE 1 Pinch Total Tape Ratio of Total Height Steel Thickness Thicknessto at Load at Reinforcement Tape Width Thickness (T1 + T2 + T3) SteelHardness break break Name Layer Type (mm) (T1) (mm) (mm) Thickness(HV0.5) (mm) (lb.) Prototype 1 - Test 1 Nylon 27 0.11 0.33 3.00 510 1.2835 Extrusion Prototype 1 - Test 2 Nylon 27 0.11 0.33 3.00 510 1.3 38Extrusion Prototype 1 - Test 3 Nylon 27 0.11 0.33 3.00 510 1.26 33Extrusion Prototype 2 - Test 1 Nylon 0.13 0.40 3.08 490 0.81 62.6Extrusion Prototype 2 - Test 2 Nylon 0.13 0.40 3.08 490 0.81 63.0Extrusion Prototype 2 - Test 3 Nylon 0.13 0.40 3.08 490 0.78 79.5Extrusion Prototype 3 - Test 1 Nylon 0.13 0.50 3.85 500 0.88 150.1Extrusion Prototype 3 - Test 2 Nylon 0.13 0.50 3.85 500 0.88 150.1Extrusion Prototype 3 - Test 3 Nylon 0.13 0.50 3.85 500 0.90 150.1Extrusion Prior Art 1 - Test 1 Film 29 0.13 0.16 1.25 1.723 22.5 PriorArt 1 - Test 2 Film 29 0.13 0.16 1.25 1.638 23.1 Prior Art 1 - Test 3Film 29 0.13 0.16 1.25 1.595 24.9 Prior Art 2 - Test 1 Film 32 0.13 0.181.38 2.360 23.2 Prior Art 2 - Test 2 Film 32 0.13 0.18 1.38 2.309 23.4Prior Art 2 - Test 3 Film 32 0.13 0.18 1.38 2.309 23.7 Prior Art 2 -Test 4 Film 32 0.13 0.18 1.38 2.352 25.0 Prior Art 2 - Test 5 Film 320.13 0.18 1.38 2.267 25.2 Prior Art 2 - Test 6 Film 32 0.13 0.18 1.382.394 25.3 Prior Art 3 - Test 1 Film 32 0.13 0.18 1.42 2.188 25.0 PriorArt 3 - Test 2 Film 32 0.13 0.18 1.42 2.231 25.3 Prior Art 3 - Test 3Film 32 0.13 0.18 1.42 2.231 25.3 Prior Art 3 - Test 4 Film 32 0.13 0.181.42 2.188 25.6 Prior Art 3 - Test 5 Film 32 0.13 0.18 1.42 2.019 25.7Prior Art 3 - Test 6 Film 32 0.13 0.18 1.42 2.104 25.8 Prior Art 3 -Test 7 Film 32 0.13 0.18 1.42 2.019 25.8 Prior Art 3 - Test 7 Film 320.13 0.18 1.42 2.315 25.9 Prior Art 4 - Test 1 Film 29 0.13 0.16 1.251.469 26.0 Prior Art 3 - Test 9 Film 32 0.13 0.18 1.42 2.188 26.3Milwaukee 48-22-7116 Nylon 27 0.13 0.19 1.48 1.759 27.0 Test 1 ExtrusionMilwaukee 48-22-7116 Nylon 27 0.13 0.19 1.48 1.759 27.2 Test 2 ExtrusionMilwaukee 48-22-7116 Nylon 27 0.13 0.19 1.48 1.770 27.5 Test 3 ExtrusionPrior Art 3 - Test 10 Film 32 0.13 0.18 1.42 2.358 27.3 Prior Art 3 -Test 11 Film 32 0.13 0.18 1.42 2.358 27.4 Prior Art 3 - Test 12 Film 320.13 0.184 1.42 2.146 27.7 Prototype 4 - Test 1 single sided 25 0.1250.34 2.72 570 27.7 film Prototype 4 - Test 2 single sided 25 0.125 0.342.72 570 27.7 film Prototype 5 - Test 1 double sided 25 0.125 0.415 3.32570 49.3 film Prototype 5 - Test 2 double sided 25 0.125 0.415 3.32 57045.0 film Prototype 6 - Test 1 single sided 25 0.106 0.304 2.87 504 0.4041.7 film Prototype 6 - Test 2 single sided 25 0.106 0.304 2.87 504 0.4041.9 film Prototype 7 - Test 1 double sided 25 0.106 0.464 4.38 504 0.40150.1 film Prototype 7 - Test 2 double sided 25 0.106 0.464 4.38 5040.40 172.1 film

Referring to FIGS. 4 and 5 , details of the Pinch Test used to generatethe data shown in Table 1, is shown and described. Pinch test system 400includes a mandrel 402, a test fixture 404, clamp assemblies 406 and408, and an aluminum support plate 410. Test fixture 404 supports a tapeblade 14 that is to be pinch tested. Test fixture 404 holds tape bladein the u-shape as shown in FIG. 5 . Clamp assembly 406 secures tapeblade 14 to test fixture 404, and clamp assembly 408 secures testfixture 404 to a testing table. During pinch testing a 10 inch longpiece of tape 14 is used. Mandrel 402 is run by an Instron TensileMachine. Test fixture 404 is a component as shown for holding tape blade14, and plate 410 is an 8 inch×4 inch×0.5 inch piece of extrudedaluminum.

To set up the pinch test, test fixture 404 is positioned so that theu-bend in tape blade 14 is located near the vertical central axis 412 ofmandrel 402, as shown in FIG. 5 . Next, tape blade 14 is removed tocontinue setup. Next, the position of mandrel 402 is located, and themaximum displacement value is set. Specifically, mandrel 402 is loweredso that it is touching the upper surface of plate 410. At this point,mandrel extension value is set to zero. Next, the mandrel 402 is raisedaway from plate 410 to a height of 0.156 inches (˜2× thickness of tapeblade 14 being tested). At this point, the mandrel extension value isset to zero again. Next, mandrel 402 is raised to a height of about ˜1.5inches above plate 410, and the exact mandrel extension value isrecorded and is set as the maximum displacement used during the pinchtest. Then the mandrel extension value is set to zero again.

During pinch testing, the machine running mandrel 402 advances mandrel402 at a rate of 1 inch per minute, and is set to stop if the loadexceeds 150 lbs. Tape blade 14 is returned to its position below mandrel402 as shown in FIG. 4 , and the ends 414 of tape blade 14 arepositioned flush against the back wall of test fixture 404. Next, thetest is started causing mandrel 402 to advance, controlled by theInstron Machine, which pinches tape blade 14 against plate 410. As shownin FIG. 5 , the computer running the mandrel 402 tracks mandreldisplacement, from which pinch height, PH, shown in FIG. 5 , iscalculated. This is run until tape 14 fails or the maximum displacementor load is reached.

FIGS. 6-9 show plots of the data shown in Table 1. As can be seen, withthe exception of prototype 4, the prototypes utilizing the thickerreinforcement layers discussed herein perform significantly better thanthe prior art tape measures utilizing the pinch testing discussedherein. Based on these tests, Applicant theorizes that the relationshipbetween thickness and load at break is exponential (or similar). At apoint along the curve, when the blade is bent over on itself, thethickness of the reinforcement layer is sufficient to cause the steel tohave a radius that is large enough not to easily snap the steel. At thatpoint, the force to break is essentially the force necessary to squishthe polymer of the reinforcement layer through the radiused steel. Thatis the point where the trend line increases dramatically.

It should be understood that the figures illustrate the exemplaryembodiments in detail, and it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for description purposes only andshould not be regarded as limiting.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only. The construction and arrangements, shown in thevarious exemplary embodiments, are illustrative only. Although only afew embodiments have been described in detail in this disclosure, manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Someelements shown as integrally formed may be constructed of multiple partsor elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied. The order or sequence of any process, logicalalgorithm, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is in no way intendedthat any particular order be inferred. In addition, as used herein, thearticle “a” is intended to include one or more component or element, andis not intended to be construed as meaning only one. As used herein,“rigidly coupled” refers to two components being coupled in a mannersuch that the components move together in a fixed positionalrelationship when acted upon by a force.

Various embodiments of the invention relate to any combination of any ofthe features, and any such combination of features may be claimed inthis or future applications. Any of the features, elements or componentsof any of the exemplary embodiments discussed above may be utilizedalone or in combination with any of the features, elements or componentsof any of the other embodiments discussed above.

What is claimed is:
 1. A tape measure comprising: a housing; a reelrotatably mounted within the housing; an elongate blade wound around thereel, the elongate blade comprising: an elongate metal core having anupper surface, a lower surface and a first thickness, T1, measuredbetween the upper surface and the lower surface, wherein the uppersurface includes a concave curved section and the lower surface includesa convex curved section; an upper reinforcement layer coupled to andcovering at least a portion of the upper surface of the elongate metalcore, the upper reinforcement layer having a second thickness, T2, andan upper surface defining the uppermost surface of the elongate blade; alower reinforcement layer coupled to and covering at least a portion ofthe lower surface of the elongate metal core, the lower reinforcementlayer having a third thickness, T3, and a lower surface defining thelowermost surface of the elongate blade; and an ink layer locatedbetween the upper surface of the elongate metal core and the upperreinforcement layer forming a series of measurement markings; whereinT2+T3≥T1; wherein the elongate blade has a pinch load threshold ofgreater than 30 lbs; a retraction mechanism coupled to the reel andconfigured to driving rewinding of the elongate blade on to the reel;and a hook assembly coupled to an outer end of the elongate blade. 2.The tape measure of claim 1, wherein T1 is 0.1 mm to 0.13 mm, and T2+T3is between 0.2 mm and 0.4 mm.
 3. The tape measure of claim 1, wherein T1is an average thickness of the elongate metal core, and T2 and T3 arethe maximum thicknesses of the upper and lower reinforcement layer. 4.The tape measure of claim 1, wherein the upper reinforcement layer islocated along at least 6 ft. of the length of the elongate metal core,wherein the lower reinforcement layer is located along at least 6 ft. ofthe length of the elongate metal core.
 5. The tape measure of claim 4,wherein the upper reinforcement layer and the lower reinforcement layerare located along an entire length of the elongate metal core.
 6. Thetape measure of claim 1, wherein the elongate metal core comprises asteel material having a hardness of 45-60 RHC, and the upper and lowerreinforcement layers comprise at least one of an extruded nylon and alaminated film.
 7. The tape measure of claim 1, wherein the elongateblade has a length less than 50 feet.
 8. The tape measure of claim 1,wherein the elongate blade has a pinch height at break of less than 1.5mm.
 9. A tape measure comprising: a housing; a reel rotatably mountedwithin the housing; an elongate blade wound around the reel comprising:an elongate metal core having an upper surface, a lower surface and ametal thickness measured between the upper surface and the lowersurface; a polymer reinforcement layer coupled to a surface of theelongate metal and extending contiguously lengthwise for at least 6 ft.along a length of the elongate metal core, the polymer reinforcementlayer having a polymer reinforcement layer thickness; an ink layerlocated between the elongate metal core and the polymer reinforcementlayer, the ink layer forming a series of measurement markings; whereinthe elongate blade has a pinch load threshold of greater than 30 lbs; aretraction mechanism coupled to the reel and configured to drivingrewinding of the elongate blade on to the reel; and a hook assemblycoupled to an outer end of the elongate blade.
 10. The tape measure ofclaim 9, wherein the elongate blade has a pinch height at break of lessthan 1.5 mm, wherein the polymer reinforcement thickness is between 0.2mm and 0.4 mm and the metal thickness is between 0.1 mm and 0.13 mm. 11.The tape measure of claim 9, wherein the elongate metal core comprises asteel material having a hardness of 45-60 RHC, and the polymerreinforcement layer comprise at least one of an extruded nylon and alaminated film.
 12. The tape measure of claim 9, wherein the polymerreinforcement layer comprises an upper portion coupled to the uppersurface of the elongate blade and a lower portion coupled to the lowersurface of the elongate blade.
 13. The tape measure of claim 9, whereinthe elongate blade has a length less than 50 feet.
 14. The tape measureof claim 9, wherein the elongate blade has a pinch load threshold ofless than 35 lbs.
 15. A tape measure comprising: a housing; a reelrotatably mounted within the housing; an elongate blade wound around thereel comprising: an elongate metal core having an upper surface, a lowersurface and a metal thickness measured between the upper surface and thelower surface; a polymer reinforcement layer at least partiallysurrounding the elongate metal core when viewed in cross-section andextending contiguously lengthwise for at least 6 ft. along a length ofthe elongate metal core, the polymer reinforcement layer having apolymer reinforcement layer thickness; an ink layer located between theelongate metal core and the polymer reinforcement layer, the ink layerforming a series of measurement markings; wherein the polymerreinforcement layer thickness is greater than the metal thickness; aretraction mechanism coupled to the reel and configured to drivingrewinding of the elongate blade on to the reel; and a hook assemblycoupled to an outer end of the elongate blade.
 16. The tape measure ofclaim 15, wherein the polymer reinforcement layer thickness is between0.2 mm and 0.4 mm and the metal thickness is between 0.1 mm and 0.13 mm.17. The tape measure of claim 16, wherein the polymer reinforcementlayer thickness is an average thickness of the polymer reinforcementlayer averaged along the length of the polymer reinforcement layer. 18.The tape measure of claim 15, wherein the elongate blade has a pinchheight at break of less than 1.5 mm.
 19. The tape measure of claim 15,wherein the elongate blade has a pinch load threshold of 30 lbs. to 50lbs.